Three-dimensional filter

Abstract

A three-dimensional filter includes a filter frame having a three-dimensional skeletal structure with a filter media connected to the skeletal structure. The filters are nestable. The skeletal structure may be trimmed and provided with walls to create standard sized filters. Methods for making the three-dimensional filter include injection molding of the skeletal structure onto the filter media, injection molding the filter media and the filter frame together in a single molding process, thermoforming a molded or extruded skeletal structure and the filter media, and needle punching a molded or extruded skeletal structure to create filter media within the skeletal structure.

I claim: 
     
       1. A three-dimensional filter comprising:
 a. a frame comprising:
 i. a wall forming a periphery that defines a space within the periphery wherein the periphery includes a pair of opposite end walls and a pair of opposite side walls, wherein each of the end walls is a single wall comprising a solid lower planar end wall portion and solid end wall peaks that protrude from and are inwardly slanted with respect to the lower planar portion, and open notches are defined between the end wall peaks and wherein each of the side walls is a single wall comprising a lower planar side wall portion and an upper side wall planar portion inwardly slanted with respect to the lower planar side wall portion; and 
 ii. a skeletal structure occupying the space within the periphery wherein the skeletal structure has peak ribs extending between the solid end wall peaks of the opposite end walls and valley ribs and extending between the solid lower planar portion of the opposite end walls, wherein the peak ribs and the valley ribs form peaks and valleys in the skeletal structure with open ends, and wherein the solid end wall peaks and the solid lower planar portion are attached to the open ends and close the open ends of the skeletal structure; and 
 
 b. a filter media connected to the skeletal structure and conforming to the peaks and valleys of the skeletal structure and terminating at the solid end wall peaks. 
 
     
     
       2. The three-dimensional filter of  claim 1 , wherein the end wall peaks extend above the lower planar portion sufficiently so that a plurality of similarly constructed three-dimensional filters can be nested for stacking. 
     
     
       3. The three-dimensional filter of  claim 1 , wherein the end walls are configured to have an open position that allows the filters to be nested for stacking and a closed position that closes the ends of the peaks and valleys when the filter is in use wherein the end walls have a hinged baffle that moves from a lowered position that corresponds to the open position of the end wall to a raised position that corresponds to the closed position of the end wall. 
     
     
       4. The three-dimensional filter of  claim 1 , wherein the end walls are configured to have an open position that allows the filters to be nested for stacking and a closed position that closes the ends of the peaks and valleys when the filter is in use wherein the end walls are disconnected from the ends of the peaks and valleys when the end walls are in the open position are connected to the ends of the peaks and valleys when the end walls are in the closed position. 
     
     
       5. The three-dimensional filter of  claim 1 , wherein the end walls are configured to have an open position that allows the filters to be nested for stacking and a closed position that closes the ends of the peaks and valleys when the filter is in use wherein the end walls are hinged to end swung away from the ends of the peaks and valleys when the end walls are in the open position are fixedly connected to the ends of the peaks and valleys when the end walls are in the closed position. 
     
     
       6. The three-dimensional filter of  claim 1 , wherein the skeletal structure includes pleated reinforcing end bands positioned at the ends of the peaks and valleys, engaging the peak ribs and the valley ribs, and extending parallel to the end walls. 
     
     
       7. The three-dimensional filter of  claim 1 , wherein the skeletal structure includes reinforcing intermediate pleated bands positioned between the end walls, engaging the peak ribs and the valley ribs, and extending diagonally to the peak ribs and the valley ribs. 
     
     
       8. The three-dimensional filter of  claim 1 , wherein the skeletal structure further includes rib supports extending between the peak ribs and the valley ribs to reinforce and maintain separation between the peak ribs and the valley ribs. 
     
     
       9. The three-dimensional filter of  claim 1 , wherein the peaks and valleys of the skeletal structure extend between the end walls, wherein the peaks and valleys have ends that include a first portion of a releasable connector, wherein the end walls include a second portion of the releasable connector, and wherein the portions of the connector connect the end walls to the skeletal structure. 
     
     
       10. The three-dimensional filter of  claim 9 , wherein the skeletal structure has intermediate connector portions that are exposed when a part of the skeletal structure is removed so that the end wall can be connected to the intermediate connector portions. 
     
     
       11. The three-dimensional filter of  claim 1 , wherein the frame and the filter media are composed of the same material. 
     
     
       12. The three-dimensional filter of  claim 11 , wherein the material for the frame, the skeleton, and the filter media is selected from the group consisting of polypropylene, polyester, and polyethylene. 
     
     
       13. The three-dimensional filter of  claim 9 , wherein the first portion of the releasable connector constitute a serpentine tab and the second portion of the releasable connector constitute a matching serpentine slot. 
     
     
       14. The three-dimensional filter of  claim 9 , wherein the end walls are connected by means of a hinge to the skeletal structure. 
     
     
       15. A three-dimensional filter comprising:
 a. a frame comprising:
 i. a wall forming a periphery that defines a space within the periphery wherein the periphery includes a pair of opposite end walls and a pair of opposite side walls, wherein each of the end walls comprises a solid lower step portion flared outwardly and downwardly and an upper portion with solid end wall peaks protruding upwardly from the lower step portion and with open notches formed between the end wall peaks, wherein the upper portion is flared upwardly and inwardly from the lower step portion; and 
 ii. a skeletal structure occupying the space within the periphery, wherein the skeletal structure has peak ribs coinciding with and extending between the solid end wall peaks of the opposite end walls and valley ribs coinciding with and extending between the solid lower step portion of the opposite end walls, wherein the peak ribs and the valley ribs form peaks and valleys in the skeletal structure with open ends, and wherein the solid end wall peaks and the solid lower step portion are attached to the open ends and close the open ends of the skeletal structure; and 
 
 b. a filter media connected to the skeletal structure and conforming to the peaks and valleys of the skeletal structure. 
 
     
     
       16. The three-dimensional filter of  claim 15 , wherein the end wall peaks extend above the lower step portion sufficiently so that a plurality of similarly constructed three-dimensional filters can be nested for stacking. 
     
     
       17. A three-dimensional filter comprising:
 a. a frame comprising:
 i. a wall forming a periphery that defines a space within the periphery; 
 ii. a skeletal structure extending into the space within the periphery and having peaks and valleys; and 
 
 b. a filter media connected to the skeletal structure and conforming to the peaks and valleys of the skeletal structure, 
 wherein the periphery includes a pair of opposite end walls and a pair of opposite side walls, wherein the peaks and valleys are pleats extending between the end walls, wherein the peaks and valleys have ends, wherein the ends of the peaks and valleys are adjacent the end walls, wherein the end walls are configured to have an open position that allows the filters to be nested for stacking and a closed position that closes the ends of the peaks and valleys when the filter is in use, and wherein the end walls have a hinged baffle that moves from a lowered position that corresponds to the open position of the end wall to a raised position that corresponds to the closed position of the end wall. 
 
     
     
       18. A three-dimensional filter comprising:
 a. a frame comprising:
 i. a wall forming a periphery that defines a space within the periphery; 
 ii. a skeletal structure extending into the space within the periphery and having peaks and valleys; and 
 
 b. a filter media connected to the skeletal structure and conforming to the peaks and valleys of the skeletal structure, 
 wherein the periphery includes a pair of opposite end walls and a pair of opposite side walls, wherein the peaks and valleys are pleats extending between the end walls, wherein the peaks and valleys have ends, wherein the ends of the peaks and valleys are adjacent the end walls, wherein the end walls are configured to have an open position that allows the filters to be nested for stacking and a closed position that closes the ends of the peaks and valleys when the filter is in use, and wherein the end walls are disconnected from the ends of the peaks and valleys when the end walls are in the open position are connected to the ends of the peaks and valleys when the end walls are in the closed position. 
 
     
     
       19. A three-dimensional filter comprising:
 a. a frame comprising:
 i. a wall forming a periphery that defines a space within the periphery; 
 ii. a skeletal structure extending into the space within the periphery and having peaks and valleys; and 
 
 b. a filter media connected to the skeletal structure and conforming to the peaks and valleys of the skeletal structure, 
 wherein the periphery includes a pair of opposite end walls and a pair of opposite side walls, wherein the peaks and valleys are pleats extending between the end walls, wherein the peaks and valleys have ends, wherein the ends of the peaks and valleys are adjacent the end walls, wherein the end walls are configured to have an open position that allows the filters to be nested for stacking and a closed position that closes the ends of the peaks and valleys when the filter is in use, and wherein the end walls are hinged to end swung away from the ends of the peaks and valleys when the end walls are in the open position are fixedly connected to the ends of the peaks and valleys when the end walls are in the closed position.